Flow-altering refiner segment

ABSTRACT

Refiner plate segments for a conical refiner may include a rotor plate segment having inlet openings disposed at one or more inlet locations on the rotor plate segment, and a stator plate segment having outlet openings disposed at one or more outlet locations on the stator plate segment. The rotor plate segment is disposed opposite the stator plate segment such that the one or more rotor plate segment refining areas and the one or more stator plate segment refining areas oppose each other, and the one or more inlet locations and the one or more outlet locations are separated by one or more refining zones formed by the rotor plate segment refining areas and the stator plate segment refining areas.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/175,752, filed Apr. 16, 2021, the contents of which is hereby incorporated herein by reference in its entirety.

BACKGROUND

Unless otherwise indicated herein, the materials described in this section are not prior art to the claims in this application and are not admitted to be prior art by inclusion in this section.

Conical mechanical refiners for treating fibrous material typically include two elements substantially opposite to one another. One of the refiner elements, the rotor, is arranged to move with respect to a stationary refiner element, the stator. Between the rotor and the stator, a refiner gap is created into which the fibrous material to be refined is fed. The refiner elements include the refining surfaces that carry out the actual refining. The refining surfaces may be one integral structure or they may consist of a plurality of refining surface segments arranged adjacent to one another forming the refining surface.

FIG. 1 is a simplified diagram illustrating a conical mechanical refiner 100. The conical mechanical refiner 100 may include a conical rotor 110, and a conical stator 120. Rotation of the conical rotor 110 around an axis of rotation “R” may be caused by a motor 130 via a shaft 135. Rotor refining plates 115 may be disposed on the surface of the conical rotor 110 and may rotate with the conical rotor 110, and stator refining plates 125 may be disposed on the surface of the conical stator 120 and may be stationary. A refining gap 140 may be formed between the conical rotor 110, and the conical stator 120.

In the case of a conical mechanical refiner 100 shown in FIG. 1, feedstock 150 such as wood pulp or cellulose is fed into the internal portion of the conical rotor 110 and into the refining gap 140 via a large number of substantially homogeneously distributed openings 117 cut across the rotor refining plates 115 or rotor refining cone. The feedstock 150 travels across the rotor refining plates 115 and stator refining plates 125. The stator refining plates 125 or stator cone also have similar openings 127 that are substantially homogeneously distributed over their surface through which the refined feedstock 155 flows out of the conical mechanical refiner 100. On the remaining surface of both rotor and stator segments or cones (the surface that surrounds all the openings), an array of bars and grooves is disposed and provides the refining treatment, as the rotor turns against the stator.

It has been observed in practice that pulp treated with the type of refiner and plate designs illustrated in FIG. 1 show that a significant proportion of fibers are either untreated or very lightly treated by the refining action, indicating that there is a significant amount of stock that possibly travels directly or almost directly through rotor openings directly into stator openings, hence being barely treated in the refining gap. There is a need to improve the flow pattern of pulp stock in this type of refiner construction in order to provide a more homogenous fiber treatment and ensure a better overall pulp development.

SUMMARY

Apparatuses for improving the flow pattern of pulp stock in a conical mechanical refiner are provided.

According to various aspects there is provided refiner plate segments for a conical mechanical refiner. In some aspects, the refiner plate segments may include: a rotor plate segment having inlet openings disposed at one or more inlet locations on the rotor plate segment and one or more rotor plate segment refining areas adjacent to the one or more inlet locations; and a stator plate segment having outlet openings disposed at one or more outlet locations on the stator plate segment and one or more stator plate segment refining areas adjacent to the one or more outlet locations.

The rotor plate segment may be disposed opposite the stator plate segment such that the one or more rotor plate segment refining areas and the one or more stator plate segment refining areas oppose each other. The one or more inlet locations and the one or more outlet locations may be separated by one or more refining zones formed by the rotor plate segment refining areas and the stator plate segment refining areas.

According to various aspects there is provided refiner plate segments for a conical mechanical refiner. In some aspects, the refiner plate segments may include: a rotor plate segment having first inlet openings disposed at a first end of the rotor plate segment, and a first rotor plate segment refining area. A first end of the first rotor plate segment refining area may be disposed adjacent to the first inlet openings in an axial direction with respect to a rotational direction of the rotor plate segment. Second inlet openings may be disposed adjacent to a second end of the first rotor plate segment refining area in the axial direction; and

The rotor plate segment may further include a second rotor plate segment refining area. A first end of the second rotor plate segment refining area may be disposed adjacent to the second inlet openings in the axial direction and a second end of the second rotor plate segment refining area may be disposed at a second end of the rotor plate segment.

The refiner plate segments may further include a stator plate segment having first outlet openings disposed at a first end of the stator plate segment, and a first stator plate segment refining area. A first end of the first stator plate segment refining area may be disposed adjacent to the first outlet openings in an axial direction with respect to the rotational direction of the rotor plate segment. Second outlet openings may be disposed adjacent to a second end of the first stator plate segment refining area in the axial direction.

The stator plate segment may further include a second stator plate segment refining area. A first end of the second stator plate segment refining area may be disposed adjacent to the second outlet openings in the axial direction and a second end of the second stator plate segment refining area may be disposed at a second end of the stator plate segment. The first end of the rotor plate segment may be disposed opposite the second end of the stator plate segment. The second end of the rotor plate segment may be disposed opposite the first end of the stator plate segment such that the first rotor plate segment refining area and the second stator plate segment refining area oppose each other, and the first stator plate segment refining area and the second rotor plate segment refining area oppose each other.

According to various aspects there is provided refiner plate elements for a conical mechanical refining apparatus. In some aspects, the refiner plate elements may include: a rotor plate element having a first rotor plate segment disposed between a first end of the rotor plate element and an intermediate location of the rotor plate element, the first rotor plate segment having a first rotor plate segment refining area; and a second rotor plate segment disposed between the intermediate location of the rotor plate element and a second end of the rotor plate element, the second rotor plate segment having a second rotor plate segment refining area. The rotor plate element may further include one or more inlet openings separated from the first rotor plate segment refining area and the second rotor plate segment refining area.

The refiner plate elements may further include: a stator plate element having a first stator plate segment disposed between a first end of the stator plate element and an intermediate location of the stator plate element, the first stator plate segment having a first stator plate segment refining area; and a second stator plate segment disposed between the intermediate location of the stator plate element and a second end of the stator plate element, the second stator plate segment having a second stator plate segment refining area. The stator plate element may further include one or more outlet openings separated from the first stator plate segment refining area and the second stator plate segment refining area.

The rotor plate element may be disposed opposite the stator plate element such that the first rotor plate segment refining area and the first stator plate segment refining area oppose each other and the second rotor plate segment refining area and the second stator plate segment refining area oppose each other. The one or more inlet openings and the one or more outlet openings may be separated by refining zones formed by the first rotor plate segment refining area and the first stator plate segment refining area, and the second rotor plate segment refining area and the second stator plate segment refining area.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects and features of the various embodiments will be more apparent by describing examples with reference to the accompanying drawings, in which:

FIG. 1 is a simplified diagram illustrating a conical mechanical refiner according to some aspects of the present disclosure;

FIG. 2 is a diagram illustrating the typical construction of rotor segments and stator segments used for a conical mechanical refiner of the type illustrated in FIG. 1;

FIG. 3 is a diagram illustrating an example of a rotor element according to some aspects of the present disclosure;

FIG. 4 is a diagram illustrating an example of a stator element according to some aspects of the present disclosure;

FIG. 5 is a diagram illustrating a simplified example of feedstock flow through a refining zone of a conical refiner having the exemplary rotor segments and stator segments according to some aspects of the present disclosure;

FIG. 6A is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common outlet opening according to some aspects of the present disclosure according to some aspects of the present disclosure;

FIG. 6B is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common inlet opening according to some aspects of the present disclosure;

FIG. 7A is a diagram illustrating examples of rotor segments having contoured side edges according to some aspects of the present disclosure;

FIG. 7B is a diagram illustrating an example of the assembled rotor segments showing inlet openings formed by the contoured side edges according to aspects of the present disclosure;

FIG. 8A is a diagram illustrating examples of stator segments having contoured side edges according to some aspects of the present disclosure;

FIG. 8B is a diagram illustrating an example of the assembled stator segments showing outlet openings formed by the contoured side edges according to some aspects of the present disclosure;

FIG. 9A is a diagram illustrating an example of a rotor segment having multiple refining areas and inlet openings according to some aspects of the present disclosure;

FIG. 9B is a diagram illustrating an example of a stator segment having multiple refining areas and outlet openings according to some aspects of the present disclosure;

FIG. 10 is a diagram illustrating an example of a blocking mechanism according to some aspects of the present disclosure;

FIG. 11 is a diagram illustrating an example of a rotor segment having bars, grooves, and obstructions according to some aspects of the present disclosure; and

FIG. 12 is a diagram illustrating an example of a stator segment having bars, grooves, and obstructions according to some aspects of the present disclosure.

DETAILED DESCRIPTION

While certain embodiments are described, these embodiments are presented by way of example only, and are not intended to limit the scope of protection. The apparatuses, methods, and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and changes in the form of the example methods and systems described herein may be made without departing from the scope of protection.

Conical mechanical refiners for treating fibrous material include a conical rotor that is arranged to move with respect to a stationary conical stator. A refiner gap is created between the conical rotor and the conical stator, into which the fibrous material to be refined is fed. The fibrous material may be fed into the middle of the conical rotor and into the refining gap through a large number of homogeneously distributed openings. The fibrous material may exit the conical mechanical refiner through similar openings that are homogeneously distributed over the surface of the conical stator. The conical rotor and the conical stator include the refining surfaces that perform the refining of the fibrous material.

FIG. 2 illustrates the typical construction of rotor segments 210 a and 210 b and stator segments 230 a and 230 b used for a conical mechanical refiner of the type illustrated in FIG. 1. The rotor segments 210 a and 210 b may be portions of the conical rotor 110 and the stator segments 230 a and 230 b may be portions of the conical stator 120. As shown in FIG. 2, inlet openings 220 a, 220 b in the rotor segments 210 a, 210 b for conducting feedstock in to the refining gap span the surface of the rotor refining areas 215 a, 215 b. Similarly, outlet openings 240 a, 240 b in the stator segments 230 a, 230 b for conducting refined feedstock out of the refining gap span the surface of the stator refining areas 235 a, 235 b. As the rotor rotates, portions of the inlet openings 220 a, 220 b of the rotor segments 210 a, 210 b can align with portions of the outlet openings 240 a, 240 b of the stator. Due to this geometry, the feedstock flow that enters through the inlet openings 220 a, 220 b in the rotor refining areas 215 a, 215 b can also exit equally through the outlet openings 240 a, 240 b in the stator refining areas 235 a, 235 b. Thus, a direct route for the feedstock in and out of the refining zone without being refined may be created when the opposing openings line up.

According to aspects of the present disclosure, the conical rotor and the conical stator may be made up of a plurality of segments that form the surfaces of the conical rotor and the conical stator. The rotor segments may include one or more inlet locations configured to conduct feedstock into the refining gap as well as one or more refining areas configured to refine the feedstock. The stator segments may include one or more outlet locations configured to conduct refined feedstock out of the refining gap as well as one or more refining areas configured to refine the feedstock. A number of refining areas may be created on the surface of the stator segments and the rotor segments. The refining areas may include various patterns of bars and grooves configured to refine the feedstock passing through the refining gap.

For each rotor segment, one or more inlet locations for feedstock may be defined outside of the refining areas such that the inlet locations are separated from the refining areas of the rotor segment, and for each stator segment, one or more outlet locations for the feedstock may be defined outside of the refining areas such that the outlet locations are separated from the refining areas of the stator segment. In some implementations, the one or more inlet locations and/or the one or more outlet locations may be covered or partially covered by the refining areas. The inlet location and the outlet location may be separated from each other by a specified axial distance along a surface of the rotor segment and/or the surface of the stator segment. Refining areas of the stator segment and the rotor segment may be disposed on the surfaces of the segments in the areas between the inlet location on the rotor segment and the outlet location on the stator segment. The feedstock thus can flow along the rotor and stator segments over the length of the refining zone in order to travel from the inlet location to the outlet location.

FIG. 3 is a diagram illustrating an example of a rotor element 300 according to some aspects of the present disclosure. A plurality of rotor elements 300 may be disposed around a conical rotor frame to form the conical rotor 110 illustrated in FIG. 1. The rotor element 300 may include rotor segments 310 a and 310 b arranged in a longitudinal direction with respect to an axis of rotation “R” of the conical rotor 110 illustrated in FIG. 1. A first end 312 a of the rotor segment 310 a may be disposed on the conical rotor frame toward a smaller end of the cone. A second end 314 a of the rotor segment 310 a may be disposed adjacent a first end 312 b of the rotor segment 310 b at an intermediate point on the conical rotor frame. A second end 314 b of the rotor segment 310 b may be disposed on the conical rotor frame towards a larger end of the cone.

Each rotor segment 310 a, 310 b may include one or more inlet openings 320 a, 320 b and one or more rotor refining areas 315 a, 315 b. The one or more inlet openings 320 a, 320 b may be disposed at the first ends 312 a, 312 b of the rotor segments 310 a, 310 b. The one or more inlet openings 320 a, 320 b may enable feedstock to flow from a back side 305 a, 305 b of the rotor segments 310 a, 310 b to the front side 306 a, 306 b of the rotor segments 310 a, 310 b and then over the refining areas 315 a, 315 b. The rotor refining areas 315 a, 315 b may include patterns of bars and grooves and/or other features designed to refine the feedstock.

While one rotor refining area 315 a, 315 b is shown on each of the rotor segment 310 a, 310 b, the rotor segments may include more than one refining area and each refining area may have the same or different patterns of bars and grooves and/or other features configured to refine feedstock. In some implementations, one or more inlet openings may be provided in areas of the rotor segments between the more than one refining areas.

In some implementations, each rotor element may include two or more rotor segments arranged in a longitudinal direction with respect to an axis of rotation “R” of the conical rotor. In some implementations, the conical mechanical refiner may accommodate only one rotor segment per rotor element. In such implementations, the rotor segment may include one inlet opening location having one or more inlet openings, or multiple inlet opening locations each including one or more inlet openings.

FIG. 4 is a diagram illustrating an example of a stator element 400 according to some aspects of the present disclosure. A plurality of stator elements 400 may be disposed on a conical stator frame surrounding the rotor element 300 thereby forming a cone around the rotor. The stator element 400 may include stator segments 410 a, 410 b arranged in a longitudinal direction with respect to an axis of rotation “R” of the conical rotor 110 illustrated in FIG. 1. A first end 412 a of the stator segment 410 a may be disposed on the conical stator frame toward a smaller end of the cone. A second end 414 a of the stator segment 410 a may be disposed adjacent a first end 412 b of the stator segment 410 b at an intermediate point on the conical rotor frame. A second end 414 b of the stator segment 410 b may be disposed on the conical stator frame towards a larger end of the cone.

Each stator segment 410 a, 410 b may include one or more outlet openings 420 a, 420 b and one or more stator refining areas 415 a, 415 b. The one or more outlet openings 420 a, 420 b may be disposed at the second ends 414 a, 414 b of the stator segments 410 a, 410 b. The stator refining areas 415 a, 415 b may include patterns of bars and grooves and/or other features designed to refine the feedstock. The one or more outlet openings 420 a, 420 b may enable feedstock to flow from the refining areas 415 a, 415 b on a front side 405 a, 405 b of the stator segments 410 a, 410 b to the back side 406 a, 406 b of the stator segments 310 a, 310 b and then exit the conical mechanical refiner.

The stator segments 410 a, 410 b may form the cone around the rotor segment 310 a, 310 b with the stator refining areas 415 a, 415 b disposed opposite the rotor refining areas 315 a, 315 b to form a refining gap (e.g., the refining gap 140 in FIG. 1) for refining feedstock between the stator segments 410 a, 410 b and the rotor segments 310 a, 310 b.

While one stator refining area 415 a, 415 b is shown on each of the stator segment 410 a, 410 b, the stator segments may include more than one refining area and each refining area may have the same or different patterns of bars and grooves and/or other features configured to refine feedstock. In some implementations, one or more outlet openings may be provided in areas of the stator segments between the more than one refining areas.

In some implementations, each stator element may include two or more stator segments arranged in a longitudinal direction with respect to an axis of rotation “R” of the conical rotor. In some implementations, the conical mechanical refiner may accommodate only one stator segment per stator element. In such implementations, the stator segment may include one outlet opening location having one or more outlet openings, or multiple outlet opening locations each including one or more outlet openings

FIG. 5 is a diagram illustrating a simplified example of feedstock flow 505 through a refining zone 530 of a conical refiner 500 having the exemplary rotor segments 510 a, 510 b and stator segments 520 a, 520 b according to some aspects of the present disclosure. As used herein, a “refining zone” 530 can be defined as the refining areas of a rotor segment and a stator segment forming a refining gap. The rotor segments 510 may be the rotor segments 310 a, 310 b illustrated in FIG. 3. The stator segments 520 a, 520 b may be the stator segments 410 a, 410 b illustrated in FIG. 4. The combination of rotor segments 510 a, 510 b may be referred to herein as a rotor element 580, and the combination of stator segments 520 a, 520 b may be referred to herein as a stator element 590. While FIG. 5 illustrates two rotor segments 510 a, 510 b forming the rotor element 580, a rotor element may be formed by one, two, or more than two rotor segments. Similarly, a stator element may be formed by one, two, or more than two stator segments.

Referring to FIG. 5, the rotor segments 510 a, 510 b may include inlet openings 512 a, 512 b, and rotor segment refining areas 514 a, 514 b. In some implementation, the inlet openings 512 a, 512 b may not extend into the rotor segment refining areas 514 a, 514 b. In some implementation, the inlet openings 512 a, 512 b may extend partially or completely into the rotor segment refining areas 514 a, 514 b. The rotor segments 510 a, 510 b may be coupled to a conical rotor frame 515. Multiple rotor segments may be coupled around the conical rotor frame 515 forming a conical shape. The conical rotor frame 515 and the rotor segments may rotate around an axis 516 driven by a motor (not shown).

The stator segments 520 a, 520 b may include outlet openings 522 a, 522 b, and stator segment refining areas 524 a, 524 b. In some implementation, the outlet openings 522 a, 522 b may not extend into the stator segment refining areas 524 a, 524 b. In some implementation, the outlet openings 522 a, 522 b may extend partially or completely into the stator segment refining areas 524 a, 524 b. The stator segments 520 a, 520 b may be coupled to a conical stator frame 525. Multiple stator segments may be coupled around the conical stator frame 525 forming a conical shape disposed around the conical shape formed by the rotor segments. In some implementations, the conical stator frame 525 and stator segments may be stationary. In some implementations, the conical stator frame 525 and stator segments may rotate around the axis 516 in a direction opposite the direction of rotation of the conical rotor frame 515 and the rotor segments.

In some implementations, each rotor segment and stator segment may form multiple refining zones. For each refining zone, one or more feedstock inlet openings in the rotor segment may be disposed at one end of the rotor segment refining area, and one or more feedstock outlet openings in the stator segment may be disposed at an opposite end of the stator segment refining area. In some implementations, the rotor segments and stator segments may form a single refining zone having one inlet and one outlet. For example, referring to FIG. 5, for each pair of rotor segments 510 a, 510 b (e.g., rotor element 580), only one inlet opening 512 a may be provided, and only one outlet opening 522 b may be provided for the corresponding pair of stator segments 520 a, 520 b (e.g., stator element 590).

In some implementations, the refining zones may not span the entire length of the rotor and stator segments. For example, rotor segments 510 a, 510 b may each include two refining areas (e.g., each refining area 514 a, 514 b may be split to form two refining areas for each segment) with inlet openings 512 a, 512 b plus additional inlet openings in the middle of the segments between the refining areas. Similarly, stator segments 520 a, 520 b may each include two refining areas (e.g., each refining area 524 a, 524 b may be split to form two refining areas for each segment) with outlet openings 522 a, 522 b plus additional outlet openings in the middle of the segments between the refining areas but prior to the additional feed openings on the rotor segments.

The area between the inlet openings and the outlet openings of a refining zone is substantially covered by a pattern of bars and grooves. Typically, the refining areas of the rotor segments and the stator segments are covered by a relatively continuous design of bars and grooves that run substantially parallel in configurations that may be straight, curved, bent, or a combination of the configurations. Each refining areas of the rotor segments and stator segments can be continuous with a constant design of bars and grooves, can be separated in sections, can have different patterns of bars and grooves, such as a coarser zone and a finer zone, and/or can have different bar heights, different bar angles, etc.

As shown in FIG. 5, pressurized feedstock 505 may be conducted through the inlet openings 512 a, 512 b in the rotor. The feed stock pressure, the effect of angles on the rotor bars and/or centrifugal force produced by the rotating rotor elements 580 may cause the feedstock 505 to pass through the refining zones 530 a, 530 b formed between the rotor segment refining areas 514 a, 514 b and the stator segment refining areas 524 a, 524 b where the feedstock 505 is refined. The combined feeding forces may cause the refined feedstock 506 to be conducted out of the conical refiner via the outlet openings 522 a, 522 b in the stator segments 520 a, 520 b. Thus, the positioning of the inlet openings 512 a, 512 b and the outlet openings 522 a, 522 b at opposite ends of the refining zones 530 a, 530 b causes the feedstock entering the conical refiner to pass through the refining zones 530 a, 530 b before exiting the conical refiner, thereby ensuring that feedstock is unlikely to pass through the conical refiner without treatment.

The inlet opening locations for each refining zone may be defined on the rotor segments and may be at a defined location along the length of the rotor segments. In some implementations, the inlet openings may be openings at/between the edges of the rotor segments when assembled on the conical rotor frame. An assembled conical-shaped rotor may have two or more inlet openings disposed around a circumference of the conical shape. In some implementations, the conical-shaped rotor may have the same number of inlet openings as the number of rotor segments (e.g., one inlet opening per rotor segment). In some implementations, each rotor segment may have multiple inlet openings. In some implementations, less than all of the rotor segments may have one or more inlet openings. The size and number of the inlet openings that create an inlet location may depend on the required feedstock flow that needs to pass through the defined refining zone that will be fed by that inlet location.

The outlet opening locations for each refining zone may be defined on the stator segments and may be at a defined location along the length of the stator segments. The outlet opening locations may be similar types of openings having the same range of parameters described above for the inlet openings on the rotor segments. The outlet opening locations may be offset relative to the rotor inlet openings by at least a distance across a refining zone. Thus, as the feedstock enters through the inlet openings in the rotor segment, the feedstock will travel some distance along the refining gap created between the rotor refining area and the stator refining area (e.g., the refining zone) before it reaches the outlet openings in the stator.

The distance between the inlet openings and outlet openings along the refining gap may be, for example, 50 mm,-300 mm or another distance. In some implementations, multiple refining zones may be disposed along the length of a gap between the rotor and stator segments, and each refining zone may have its own inlet and outlet location with the rotor and stator refining areas spanning between them.

In some implementations, two or more refining zones may have a common outlet opening or inlet opening, for example, at a mid-point between two rotor segments or two stator segments, when the feedstock flow travel towards or away from each segment, respectively. FIG. 6A is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common outlet opening according to some aspects of the present disclosure. Referring to FIG. 6A, the rotor element 610 may include rotor segments 610 a, 610 b. The stator element 620 may include stator segments 620 a, 620 b.

Inlet openings 612 a, 612 b may be disposed at locations at opposite ends of the rotor element 610 in each of rotor segments 610 a, 610 b. Outlet openings 622 a may be disposed at a location at an intermediate point between the stator segments 620 a, 620 b. As illustrated in FIG. 6A, the feedstock 605 may be conducted into the inlet opening 612 a and travel through the refining zone 630 a toward the mid-point between the rotor segments 610 a, 610 b and the stator segments. Concurrently, feedstock 605 may be conducted into the inlet opening 612 b at the opposite end of the rotor element 610 and travel in an opposite direction through the refining zone 630 b toward the mid-point between the rotor segments 610 a, 610 b and the stator segments 620 a, 620 b. Refined feedstock 606 from refining zones 630 a, 630 b may exit the conical refiner via the common outlet opening 622.

FIG. 6B is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common inlet opening according to some aspects of the present disclosure. Referring to FIG. 6B, the rotor element 660 may include rotor segments 660 a, 660 b. The stator element 670 may include stator segments 670 a, 670 b. The feedstock 655 may be conducted into the common inlet opening 662 disposed at a location at an intermediate point between the rotor segments 660 a, 660 b.

As illustrated in FIG. 6B, the feedstock 605 may travel in one direction through the refining zone 680 a toward an end of the rotor segment 660 a and a corresponding end of the stator segment 670 a. Concurrently, the feedstock 655 may travel in an opposite direction through the refining zone 680 b toward an end opposite of the rotor segment 660 b and a corresponding end of the stator segment 670 b. Refined feedstock 656 from refining zones 680 a may exit the conical refiner via outlet opening 672 a in the stator segment 670 a and refined feedstock 656 from refining zones 680 b may exit the conical refiner via outlet opening 672 b in the stator segment 670 b.

In some implementations, feedstock may flow from the smaller end of the conical shape towards the larger end of the conical shape in all refining zones. In some implementations, the feedstock may flow from the larger end of the conical shape towards the smaller end of the conical shape in all refining zones. In some implementations, feedstock may flow from the smaller end of the conical shape towards the larger end of the conical shape in some refining zones, while feedstock may flow from the larger end of the conical shape towards the smaller end of the conical shape in other refining zones.

In some implementations, the inlet openings and/or the outlet openings may be openings at/between the edges of the rotor segments when assembled on the conical rotor frame. contoured side edges that create the openings when segments are assembled as a set. FIG. 7A is a diagram illustrating examples of rotor segments having contoured side edges according to some aspects of the present disclosure. Referring to FIG. 7A, rotor element 710 may include rotor segments 712, 714. Similarly, rotor element 720 may include rotor segments 722, 724. Each rotor segment may include a refining area having a width W1 in a radial direction with respect to a rotational direction of the rotor segment and a length L1 in an axial direction with respect to the rotational direction of the rotor segment. The width W1 of the refining area may vary along the length L1 of the rotor segment. Each rotor segment may also include an inlet area having a width W2 in a radial direction with respect to a rotational direction of the rotor segment and a length L2 in an axial direction with respect to the rotational direction of the rotor segment. The width W2 of the inlet area may vary along the length L2 of the rotor segment. Rotor segment 712 of rotor element 710 may include contoured side edges 712 a, 712 b. Similarly, rotor segment 714 of rotor element 710 may include contoured side edges 714 a, 714 b. Rotor segments 722, 724 of corresponding rotor element 720 may include contoured side edges 722 a, 722 b and contoured side edges 724 a, 724 b, respectively.

When assembled on the conical rotor frame, the contoured side edges form the inlet openings. For example, when rotor element 710 is assembled to the conical rotor frame adjacent to rotor element 720, contoured side edge 712 a and contoured side edge 722 a form an inlet opening. Similarly, contoured side edge 714 a and contoured side edge 724 a form an inlet opening. FIG. 7B illustrates an example of the assembled rotor segments showing inlet openings 750, 760 formed by the contoured side edges according to aspects of the present disclosure. As additional rotor segments are assembled to the conical rotor frame additional inlet openings may be formed between adjacent rotor segments.

In some implementations, each rotor segment may include one contoured side edge and one non-contoured edge (e.g., a substantially straight side edge). In such implantations, when assembled to the conical rotor frame, the one contoured edge of the rotor segment may form the inlet openings together with the non-contoured edge of the adjacent rotor segment.

FIG. 8A is a diagram illustrating examples of stator segments having contoured side edges according to some aspects of the present disclosure. Referring to FIG. 8A, stator element 810 may include stator segments 812, 814. Similarly, stator element 820 may include stator segments 822, 824. Each stator segment may include a refining area having a width W3 in a radial direction with respect to a rotational direction of a rotor of the conical mechanical refiner and a length L3 in an axial direction with respect to the rotational direction of the rotor of the conical mechanical refiner. The width W3 of the refining area may vary along the length L3 of the stator segment. Each stator segment may also include an outlet area having a width W4 in a radial direction with respect to a rotational direction of the rotor of the conical mechanical refiner and a length L4 in an axial direction with respect to the rotational direction of the rotor of the conical mechanical refiner. The width W4 of the outlet area may vary along the length L4 of the stator segment. Stator segment 812 of stator element 810 may include contoured side edges 812 a, 812 b. Similarly, stator segment 814 of stator element 810 may include contoured side edges 814 a, 814 b. Stator segments 822, 824 of corresponding stator element 820 may include contoured side edges 822 a, 822 b and contoured side edges 824 a, 824 b, respectively.

When assembled on the conical stator frame, the contoured side edges form the outlet openings. For example, when stator element 810 is assembled to the conical stator frame adjacent to stator element 820, contoured side edge 812 a and contoured side edge 822 a form an outlet opening. Similarly, contoured side edge 814 a and contoured side edge 824 a form an outlet opening. FIG. 8B illustrates an example of the assembled stator segments showing outlet openings 850, 860 formed by the contoured side edges according to aspects of the present disclosure. As additional stator segments are assembled to the conical stator frame additional outlet openings may be formed between adjacent stator segments.

In some implementations, each stator segment may include one contoured side edge and one non-contoured edge (e.g., a substantially straight side edge). In such implantations, when assembled to the conical stator frame, the one contoured edge of the stator segment may form the inlet openings together with the non-contoured edge of the adjacent stator segment.

FIGS. 9A and 9B are diagrams illustrating examples of a rotor segment 910 and a stator segment 950 having multiple refining areas and inlet and outlet openings according to some aspects of the present disclosure. Referring to FIG. 9A, the rotor segment 910 may include a first refining area 915 a, a second refining area 915 b, first inlet openings 920 a, and second inlet openings 920 b, The first inlet openings 920 a may be disposed at a first end 916 of the first refining area 915 a and separated from the first refining area 915 a in an axial direction with respect to a direction of rotation of the rotor of the conical mechanical refiner. The second inlet openings 920 b may be disposed between a second end 917 of the first refining area 915 a and a first end 918 of the second refining area 915 b and separated from both the first refining area 915 a and the second refining area 915 b in the axial direction with respect to a direction of rotation of the rotor of the conical mechanical refiner.

Similarly, as shown in FIG. 9B, the stator segment 950 may include a first refining area 955 a, a second refining area 955 b, first outlet openings 960 a, and second outlet openings 960 b, The first outlet openings 960 a may be disposed between a second end 956 of the first refining area 955 a and a first end 957 of the second refining area 955 b and separated from both the first refining area 955 a and the second refining area 955 b in an axial direction with respect to a direction of rotation of the rotor of the conical mechanical refiner. The second outlet openings 960 b may be disposed at a second end 958 of the second refining area 915 b and separated from the second refining area 915 b in the axial direction with respect to a direction of rotation of the rotor of the conical mechanical refiner.

While FIGS. 9a and 9B illustrated rotor segments and stator segments having two refining areas and two sets of inlet or outlet openings, more than two refining areas and/or two sets of inlet or/or outlet openings may be used without departing from the scope of the present disclosure.

As can be seen from FIGS. 9A and 9B, when the rotor segment 910 and the stator segment 950 are disposed opposite each other as assembled on a rotor frame and a stator frame, respectively, of a conical mechanical refiner, the inlet openings 920 a of the rotor segment 910 and the outlet openings 960 a of the stator segment 950 will be separated by a refining zone formed by the refining area 915 a of the rotor segment 910 and the refining are 955 a of the stator segment 950. Similarly, the inlet openings 920 b of the rotor segment 910 and the outlet openings 960 b of the stator segment 950 will be separated by a refining zone formed by the refining area 915 b of the rotor segment 910 and the refining are 955 b of the stator segment 950.

The rotor and stator segments may include any combination and number of inlet port locations and outlet port locations provided that the configuration causes flow to travel from inlet port locations and outlet port locations through refining zones (e.g., refining zones having a length of 50 mm, 300 mm, or another length). The number of refining zones formed by the rotor and stator segments may be limited only by the available area on the rotor and stator segments.

Aspects of the present disclosure may provide a blocking mechanism to prevent feedstock from flowing between adjacent inlet openings on the rotor and outlet openings on the stator. Referring back to FIG. 5, feedstock 505 conducted through a middle rotor inlet opening 512 b may exit the conical refiner via middle stator outlet opening 522 a without flowing through a refining zone (e.g., refining zone 530 b). In order to prevent the flow-through of unrefined feedstock, the area between the middle stator outlet opening 522 a and the middle rotor inlet opening 512 b may be blocked by an element constructed to help prevent the feedstock from going directly from the inlet into the outlet. The blocking element may cause feedstock entering the middle rotor inlet opening 512 b to flow only towards an outer stator outlet opening (e.g., stator outlet opening 522 b) through the refining zone.

FIG. 10 is a diagram illustrating an example of a blocking mechanism 1000 according to some aspects of the present disclosure. Referring to FIG. 10, a rotor segment 1010 may include an inlet opening 1020. A stator segment 1030 may include an outlet opening 1040. In order to prevent feedstock conducted through the inlet opening 1020 from directly exiting through the outlet opening 1040, a blocking mechanism 1050 may include a ridge 1015 protruding from the rotor segment 1010 and a corresponding ridge 1035 protruding from the stator segment 1030.

While FIG. 10 illustrates one example of a blocking mechanism, any element or group of elements constructed to prevent the flow-through of unrefined feedstock between adjacent inlet openings on the rotor and outlet openings on the stator may be used without departing from the scope of the present disclosure. As the rotor rotates, the ridge 1015 protruding from the rotor segment 1010 and the ridge 1035 protruding from the stator segment 1030 substantially block the flow of feedstock from the inlet opening 1020 to the outlet opening 1040 without making contact with each other.

An alternate method may use a pattern of bars and grooves to seal off the flow going in directly from the inlet opening to the outlet opening. For example, the pumping effect of angled bars may be utilized, and dams or other obstructions that limit the ability for feedstock flow to pass through that area may be added. Other possible methods may be utilized without departing from the scope of the present disclosure. FIG. 11 illustrates an example of a rotor segment 1100 having bars, grooves, and obstructions 1110 to prevent the flow-through of unrefined feedstock. FIG. 12 illustrates an example of a stator segment 1200 having bars, grooves, and obstructions 1210 to prevent the flow-through of unrefined feedstock.

While the above examples have been explained in terms of multiple rotor elements and stator elements that are assembled to form conical-shaped rotors and conical-shaped stators, in some implementations, a conical-shaped rotor and/or a conical-shaped stator may be formed as a single conical-shaped element without departing from the scope of the present disclosure.

The examples and embodiments described herein are for illustrative purposes only. Various modifications or changes in light thereof will be apparent to persons skilled in the art. These are to be included within the spirit and purview of this application, and the scope of the appended claims, which follow. 

What is claimed is:
 1. Refiner plate segments for a conical mechanical refiner, the refiner plate segments comprising: a rotor plate segment comprising: inlet openings disposed at one or more inlet locations of the rotor plate segment; and one or more rotor plate segment refining areas adjacent to the one or more inlet locations; and a stator plate segment comprising: outlet openings disposed at one or more outlet locations of the stator plate segment; and one or more stator plate segment refining areas adjacent to the one or more outlet locations, wherein the rotor plate segment is disposed opposite the stator plate segment such that the one or more rotor plate segment refining areas and the one or more stator plate segment refining areas oppose each other, and wherein the one or more inlet locations and the one or more outlet locations are separated by one or more refining zones formed by the rotor plate segment refining areas and the stator plate segment refining areas.
 2. The refiner plate segments of claim 1, wherein: the inlet openings are separated from the one or more rotor plate segment refining areas, and the outlet openings are separated from the one or more stator plate segment refining areas.
 3. The refiner plate segments of claim 1, wherein: the inlet openings are configured to conduct feedstock into a first end of a refining zone between the rotor plate segment refining area and the stator plate segment refining area, and the outlet openings are configured to conduct refined feedstock out of a second end of the refining zone, wherein the inlet openings are separated from the outlet openings by the refining zone in an axial direction with respect to a rotational direction of a rotor of the conical mechanical refiner.
 4. The refiner plate segments of claim 1, wherein the rotor plate segment refining area and the stator plate segment refining area comprise a plurality of features configured to refine feedstock.
 5. The refiner plate segments of claim 1, wherein a plurality of rotor plate segments are assembled on a first conical support frame to form a conical-shaped rotor, and a corresponding plurality of stator plate segments are assembled on a second conical support frame to form a conical-shaped stator surrounding the conical-shaped rotor.
 6. The refiner plate segments of claim 5, wherein selected ones of the plurality of rotor plate segments are configured without inlet openings and selected ones of the plurality of stator plate segments are configured without outlet openings, wherein the selected ones of the plurality of rotor plate segments and the selected ones of the plurality of stator plate segments are selected based on feedstock flow needed to pass through refining zones formed by refining areas of the plurality of rotor plate segments and the plurality of stator plate segments.
 7. The refiner plate segments of claim 1, wherein: the inlet openings of the rotor plate segment are configured to permit feedstock to flow from a back side of the rotor plate segment into a refining gap formed by the rotor plate segment refining area and the stator plate segment refining area, and the outlet openings of the stator plate segment are configured to permit feedstock to flow from the refining gap to a backside of the stator plate segment.
 8. The refiner plate segments of claim 1, wherein the inlet openings are formed by one or more openings in the rotor plate segment separated from the one or more rotor plate segment refining areas.
 9. The refiner plate segments of claim 1, wherein the inlet openings are formed by one or more contoured edges of the rotor plate segment separated from the one or more rotor plate segment refining areas.
 10. The refiner plate segments of claim 1, wherein the outlet openings are formed by one or more openings in the stator plate segment separated from the one or more stator plate segment refining areas.
 11. The refiner plate segments of claim 1, wherein the outlet openings are formed by one or more contoured edges of the stator plate segment separated from the one or more stator plate segment refining areas.
 12. Refiner plate segments for a conical mechanical refiner, the refiner plate segments comprising: a rotor plate segment comprising: first inlet openings disposed at a first end of the rotor plate segment; a first rotor plate segment refining area, a first end of the first rotor plate segment refining area being disposed adjacent to the first inlet openings in an axial direction with respect to a rotational direction of the rotor plate segment; second inlet openings disposed adjacent to a second end of the first rotor plate segment refining area in the axial direction; and a second rotor plate segment refining area, a first end of the second rotor plate segment refining area being disposed adjacent to the second inlet openings in the axial direction and a second end of the second rotor plate segment refining area being disposed at a second end of the rotor plate segment; and a stator plate segment comprising: first outlet openings disposed at a first end of the stator plate segment; and a first stator plate segment refining area, a first end of the first stator plate segment refining area being disposed adjacent to the first outlet openings in an axial direction with respect to the rotational direction of the rotor plate segment; second outlet openings disposed adjacent to a second end of the first stator plate segment refining area in the axial direction; and a second stator plate segment refining area, a first end of the second stator plate segment refining area being disposed adjacent to the second outlet openings in the axial direction and a second end of the second stator plate segment refining area being disposed at a second end of the stator plate segment, wherein the first end of the rotor plate segment is disposed opposite the second end of the stator plate segment, and wherein the second end of the rotor plate segment is disposed opposite the first end of the stator plate segment such that the first rotor plate segment refining area and the second stator plate segment refining area oppose each other, and the first stator plate segment refining area and the second rotor plate segment refining area oppose each other.
 13. The refiner plate segments of claim 12, further comprising a blocking mechanism configured to disrupt a feedstock flow path from the second inlet openings to the second outlet openings.
 14. The refiner plate segments of claim 12, wherein: the first and second inlet openings are separated from the first and second rotor plate segment refining areas, respectively, and the first and second outlet openings are separated from the first and second stator plate segment refining areas, respectively.
 15. The refiner plate segments of claim 14, wherein the first and second inlet openings are disposed at opposite ends of refining zones formed by the first and second rotor plate segment refining areas and the first and second stator plate segment refining areas from the first and second outlet openings, respectively.
 16. The refiner plate segments of claim 12, wherein: the first inlet openings are configured to conduct feedstock into a first end of a first refining zone between the first rotor plate segment refining area and the second stator plate segment refining area, the second inlet openings are configured to conduct feedstock into a first end of a second refining zone between the second rotor plate segment refining area and the first stator plate segment refining area, the first outlet openings are configured to conduct refined feedstock out of a second end of the first refining zone, wherein the first inlet openings are separated from the first outlet openings by the first refining zone in an axial direction with respect to a rotational direction of a rotor of the conical mechanical refiner, and the second outlet openings are configured to conduct refined feedstock out of a second end of the second refining zone, wherein the second inlet openings are separated from the second outlet openings by the second refining zone in an axial direction with respect to a rotational direction of a rotor of the conical mechanical refiner.
 17. The refiner plate segments of claim 12, wherein a plurality of rotor plate segments are assembled on a first conical support frame to form a conical-shaped rotor, and a corresponding plurality of stator plate segments are assembled on a second conical support frame to form a conical-shaped stator surrounding the conical-shaped rotor.
 18. The refiner plate segments of claim 17, wherein selected ones of the plurality of rotor plate segments are configured without inlet openings and selected ones of the plurality of stator plate segments are configured without outlet openings, wherein the selected ones of the plurality of rotor plate segments and the selected ones of the plurality of stator plate segments are selected based on feedstock flow needed to pass through refining zones formed by refining areas of the plurality of rotor plate segments and the plurality of stator plate segments.
 19. The refiner plate segments of claim 12, wherein: the first and second inlet openings of the rotor plate segment are configured to permit feedstock to flow from a back side of the rotor plate segment into refining gaps formed by the rotor plate segment refining areas and the stator plate segment refining areas, and the first and second outlet openings of the stator plate segment are configured to permit feedstock to flow from the refining gaps to a backside of the stator plate segment.
 20. Refiner plate elements for a conical mechanical refining apparatus, the refiner plate elements, comprising: a rotor plate element comprising: a first rotor plate segment disposed between a first end of the rotor plate element and an intermediate location of the rotor plate element, the first rotor plate segment having a first rotor plate segment refining area; and a second rotor plate segment disposed between the intermediate location of the rotor plate element and a second end of the rotor plate element, the second rotor plate segment having a second rotor plate segment refining area, wherein the rotor plate element further comprises one or more inlet openings separated from the first rotor plate segment refining area and the second rotor plate segment refining area; and a stator plate element comprising: a first stator plate segment disposed between a first end of the stator plate element and an intermediate location of the stator plate element, the first stator plate segment having a first stator plate segment refining area; and a second stator plate segment disposed between the intermediate location of the stator plate element and a second end of the stator plate element, the second stator plate segment having a second stator plate segment refining area, wherein the stator plate element further comprises one or more outlet openings separated from the first stator plate segment refining area and the second stator plate segment refining area, wherein the rotor plate element is disposed opposite the stator plate element such that the first rotor plate segment refining area and the first stator plate segment refining area oppose each other and the second rotor plate segment refining area and the second stator plate segment refining area oppose each other, and wherein the one or more inlet openings and the one or more outlet openings are separated by refining zones formed by the first rotor plate segment refining area and the first stator plate segment refining area, and the second rotor plate segment refining area and the second stator plate segment refining area.
 21. The refiner plate elements of claim 20, wherein one or more first inlet openings for the rotor plate element are disposed in the first rotor plate segment at the first end of the rotor plate element, and wherein one or more second inlet openings for the rotor plate element are disposed in the second rotor plate segment at the intermediate location of the rotor plate element.
 22. The refiner plate elements of claim 20, wherein one or more first inlet openings for the rotor plate element are disposed in the first rotor plate segment at the first end of the rotor plate element, wherein one or more second inlet openings for the rotor plate element are disposed in the second rotor plate segment at the second end of the rotor plate element, and wherein the one or more outlet openings for the stator plate element are disposed in the first stator plate segment or the second stator plate segment at the intermediate location of the stator plate element.
 23. The refiner plate elements of claim 20, wherein one or more first inlet openings for the rotor plate element are disposed in the first rotor plate segment or the second rotor plate segment at the intermediate location of the rotor plate element, wherein one or more first outlet openings for the stator plate element are disposed in the first stator plate segment at the first end of the stator plate element, and wherein one or more second outlet openings for the stator plate element are disposed in the second stator plate segment at the intermediate location of the stator plate element.
 24. The refiner plate elements of claim 20, wherein the one or more inlet openings of the rotor plate element are configured to permit feedstock to flow from a back side of the rotor plate element into refining gaps formed by the first and second rotor plate segment refining areas and the first and second stator plate segment refining areas, and the one or more outlet openings of the stator plate element are configured to permit feedstock to flow from the refining gaps to a backside of the stator plate element. 